Ford Falcon. Manual — part 497

501-25G-7

Body Repairs - Noise, Vibration and Harshness

501-25G-7

DESCRIPTION AND OPERATION (Continued)

Item

Description

4

Air cleaner

5

Resonator

The volume and length of intake systems are

matched exactly. No changes may be carried out

during service or repair work. When attaching

components (hoses and tubes), pay attention that

all connections are air-tight.
The surfaces of all components affected by the

strong pressure variations in the intake system

are especially subject to strong oscillations.
The effects of temperature, such as warming of

the air filter housing can cause changes in the

rigidity of surfaces.
In order to prevent solid body sound caused by

surface oscillations of the intake system from

being transmitted to the vehicle body, the

following points must be observed during service:

The whole intake system must be isolated

from the bodywork and mounted in rubber

bushes without tension.
The air channels of the intake system must

not contact the bodywork components.
Insert foam insulation at points of contact with

bodywork or other components.

Exhaust system

Exhaust system construction

under some circumstances can also cause a noise

Item

Description

problem. For this reason it is important that the

1

Catalytic converter

exhaust system is installed free of strain.

2

Front silencer

The rubber mountings must not be over-stretched.

3

Rear silencer

The exhaust manifold and catalytic converter (if it

Exhaust systems must be installed without strain.

is mounted directly at the engine) must have a

solid connection to the engine (no splits in

NOTE: The rubber mountings in which an exhaust

brackets).

system is suspended also transmit oscillations and

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01/2003 2002.50 BA Falcon

501-25G-8

Body Repairs - Noise, Vibration and Harshness

501-25G-8

DESCRIPTION AND OPERATION (Continued)

Simple problem testing:

Correct installation of the windows.

Remove all mountings from which the exhaust

Correct installation of the seals.

system is suspended.

Further points

Support the exhaust system with rope at two

Openings into the engine compartment

positions at the most.

Door and window sealing

Check the noise level in the passenger

Heater and ventilation openings

compartment during a road test.

Sliding roof drainage hoses

If this solves the problem, the exhaust

The side- and crossmembers in the body

mountings are the source of the noise.

structure are often linking channels allowing

Put back the exhaust supports one at a time,

sound transmission. Possible corrective measures

and road test the vehicle after fitting each

are:

one.

Installation of dividing walls at critical points

By proceeding in steps in this way, the

such as the joint between the sidemember

mounting that is causing the noise in the

and the A-pillar in order to ensure good air

passenger compartment can be found.

borne sound insulation.

Bodywork

Installation of foam plugs in affected areas.
Filling hollow sections with foam.

Function

NOTE: NOTE: Foam pieces and foam filling are used

Different types of demand are made on the

in production to seal air borne sound transmission

bodywork of a vehicle, particularly when it is being routes. If wind, tyre, engine or road noise is a

driven. Predominant here are vibrations caused

problem, the position of the pieces of foam should be

mainly by other vehicle components, such as the

checked.

engine and mountings. The bodywork is therefore

one of the most important vehicle components

where NVF is concerned.
The vehicle components described so far were,

according to their function, individual

self-contained noise sources. The bodywork

however, connects and houses all the vehicle

components.
The bodywork is subject to vibration from both air

borne sound and solid body sound.
The bodywork must absorb all oscillations and

impulses from all components and if possible

transmit none of these to the vehicle interior.
The largest proportion of NVH behaviour of a

bodyshell is in the steel panels of the roof, sides

and floor. They are strongly stimulated by the

bodyshell structure and work like a loudspeaker

transmitting noise.

Further demands on the bodywork

Good crash behaviour
Large interior space
Corrosion resistance
Low weight
Good aerodynamic shape

A compromise must be made on some of these

points. One example is between high body rigidity for

good NVH performance and good energy absorption

in an accident by the use of crumple zones.
Example:

Watertight does not mean sound tight, therefore

the following points must be taken into account:

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01/2003 2002.50 BA Falcon

501-26-1

Body Repairs- Tolerance Checks

501-26-1

SECTION 501-26: Body Repairs- Tolerance Checks

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

WELD INFORMATION

Dimensional Check Underbody Plan View . . . . . . . . . . . . . . . . . . . 501-26-2

Dimensional Check Underbody Side View . . . . . . . . . . . . . . . . . . . 501-26-3

Dimensional Check Underbody Wagon Plan View . . . . . . . . . . . . . . . . 501-26-4

Dimensional Check Underbody Wagon Side View . . . . . . . . . . . . . . . . 501-26-5

Dimensional Check Front End . . . . . . . . . . . . . . . . . . . . . . . ...501-26-6

Dimensional Check Rear End . . . . . . . . . . . . . . . . . . . . . . . . 501-26-7

Dimensional Check Wagon Liftgate Aperture . . . . . . . . . . . . . . . . . . 501-26-8

Dimensional Check Body Shell Width Sedan . . . . . . . . . . . . . . . . . . 501-26-9

Dimensional Check Body Shell Width Wagon . . . . . . . . . . . . . . . . . .501-26-10

Dimensional Check Front Door Aperture . . . . . . . . . . . . . . . . . . . .501-26-11

Dimensional Check Rear Door Aperture Sedan . . . . . . . . . . . . . . . . ..501-26-12

Dimensional Check Rear Door Aperture Wagon . . . . . . . . . . . . . . . . .501-26-13

Body Gap Dimensions Front End 1 . . . . . . . . . . . . . . . . . . . . . .501-26-14

Body Gap Dimensions Front End 2 . . . . . . . . . . . . . . . . . . . . . .501-26-15

Body Gap Dimensions Front Side . . . . . . . . . . . . . . . . . . . . . ...501-26-16

Body Gap Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .501-26-17

Body Gap Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .501-26-18

Body Gap Dimension Rear Quarter Panel . . . . . . . . . . . . . . . . . . ...501-26-19

Body Gap Dimension Rear End . . . . . . . . . . . . . . . . . . . . . . ...501-26-20

501-26-2

Body Repairs - Tolerance Checks

501-26-2

WELD INFORMATION

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